Method of catalyst reduction in a hydrogen plant

Abstract

The present invention relates to a method of reducing a catalyst utilized in a hydrogen plant. More specifically, the invention relates the reduction of a catalyst employed in the steam methane reformer.

What is claimed is: 
     
       1. A method of starting up an integrated hydrogen or syngas plant including a reactor having a catalyst therein, comprising:
 a first step of providing a catalyst reduction fluid selected from methanol, ammonia, and urea, and introducing the catalyst reduction fluid into a steam stream through liquid spray quench nozzles; 
 introducing the mixture of catalyst reduction fluid and steam stream and reducing a catalyst disposed within the reactor, until the catalyst is reduced; and 
 thereafter in a separate second step of admitting a reactor feedstock and steam stream into the reactor where reforming is carried out and wherein liquid water is introduced through the liquid spray quench nozzles utilized for introducing the mixture of catalyst reduction fluid into the steam stream in the first step as a means of controlling the temperature of a combined reactant feedstock and steam stream. 
 
     
     
       2. The method of  claim 1 , where the feedstock is selected from natural gas, naphtha and LPG. 
     
     
       3. The method of  claim 1 , where the reactor is a pre-reformer or a steam methane reformer having the catalyst therein. 
     
     
       4. The method of  claim 1 , wherein the catalyst is nickel-based. 
     
     
       5. The method of  claim 1 , wherein the temperature at an inlet of the reactor is in the range of 900−1300° F. during normal steady state operation the second step. 
     
     
       6. The method of  claim 1 , comprising: removing a synthesis gas at the outlet of the reactor during the second step at a temperature in the range of 1400−1800° F. 
     
     
       7. The method of  claim 1 , wherein a minimum steam to reductant molar ratio in the range of 20:1 to 30:1 is attained. 
     
     
       8. The method of  claim 1 , wherein a minimum steam to reductant molar ratio in the range of 20:1 to 23:1 is attained. 
     
     
       9. The method of  claim 1 , wherein the catalyst reduction fluid is stored in a vessel normally used for a plant feedstock. 
     
     
       10. The method of  claim 1 , wherein the catalyst reduction fluid is pumped from storage using a pump utilized in normal operations for a plant feedstock. 
     
     
       11. The method of  claim 10 , wherein the catalyst reduction fluid is further purified by routing said reductant fluid through an activated carbon bed filter. 
     
     
       12. The method of  claim 1 , wherein a steam to carbon ratio of the reactor feedstock and steam stream is in the range of about 1.5 to 3.5 during the second step.